SOEC Syngas Generation With Partial CO2 Conversion for Hydroformylation
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Solution Overview
Problem
Existing methods for generating low-module syngas for hydroformylation reactions are costly, complex, and pose safety risks due to the transportation and handling of toxic and flammable gases, while conventional electrolysis systems face inefficiencies and high costs for CO2 separation.
Innovation Solution
A method utilizing solid oxide electrolysis cells (SOECs) to generate syngas on-site by partially converting CO2 and H2O into CO and H2, utilizing a CO2-expanded liquid medium (CXL) for enhanced hydroformylation reactions, avoiding costly separation processes and enabling on-site production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If CO2 is fully converted to CO using SOEC, then pure CO is obtained, but carbon deposits form in the cell requiring expensive PSA separation
Solution Approach 1:
The patent applies partial conversion by operating the SOEC at moderate conversion levels (25-75% CO2 conversion) rather than full conversion. This partial action prevents excessive carbon deposition while still generating sufficient CO for the reaction, eliminating the need for expensive PSA separation units while maintaining adequate CO purity for hydroformylation processes
2Reliability
If traditional syngas production and storage methods are used, then CO supply is ensured, but safety risks and transportation costs increase
Solution Approach 1:
The patent uses CO2 as an intermediary substance that serves dual purposes: it is the feedstock for CO generation via SOEC electrolysis and simultaneously acts as the expansion gas for creating the CXL reaction medium. This eliminates the need for separate CO storage and handling systems, removing safety risks associated with toxic and flammable syngas transportation while ensuring reliable CO supply directly at the reaction site
Solution Approach 2:
The system generates its own CO supply on-demand through SOEC electrolysis of CO2 at the point of use, making the process self-sufficient. The CO2 feedstock is converted to CO as needed for the hydroformylation reaction, eliminating dependence on external syngas production facilities and their associated safety and transportation infrastructure
3Productivity
If CO2 is used as expansion gas for CXL media, then reaction rate increases, but source of CO2 and CO must be provided separately
Solution Approach 1:
The patent merges the CO generation function and the CXL expansion gas supply function into a single integrated process. The SOEC electrolyzes CO2 to produce CO, and the unconverted CO2 naturally remaining in the gas stream serves as the expansion gas for creating the CXL reaction medium. This consolidation eliminates the need for separate CO and CO2 supply systems, reducing front-end complexity while maintaining the productivity benefits of CXL media
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, safe, and cost-effective generation of syngas with desired CO:H2 ratios, enhancing reaction rates and selectivity in hydroformylation processes, while reducing environmental impact and operational costs.
Implementation Method 1
CO2 can be electrolyzed to CO. Furthermore, using the same SOEC or SOEC stack, H2 can be generated from H2O
Implementation Method 2
Pressurizing an organic solvent with CO2 makes the solvent expand, and the diffusivity and solubility of other (reactant) gases are increased compared to the neat solvent
Data Source
AI summary
A method for the generation of a gas mixture including carbon monoxide, carbon dioxide and optionally hydrogen for use in hydroformylation plants or in carbonylation plants, including mixing an optional steam with carbon dioxide in the desired molar ratio, feeding the resulting gas to a solid oxide electrolysis cell (SOEC) or an SOEC stack at a sufficient temperature for the cell or cell stack to operate while effecting a partial conversion of carbon dioxide to carbon monoxide and optionally of steam to hydrogen, removing some or all the remaining steam from the raw product gas stream by cooling the raw product gas stream and separating the remaining product gas from a liquid, and using the gas mixture containing CO and CO2 for liquid phase synthesis reactions utilizing carbon monoxide as one of the reactants while recycling CO2 to the SOEC or SOEC stack.